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This paper uses a two-scale material modeling approach to investigate fatigue crack initiation and propagation of the material X10CrMoVNb9-1 (P91) under cyclic loading at room temperature. The Voronoi tessellation method was implemented to generate an artificial microstructure model at the microstructure level, and then, the finite element (FE) method was applied to identify different stress distributions. The stress distributions for multiple artificial microstructures was analyzed by using the physically based Tanaka–Mura model to estimate the number of cycles for crack initiation. Considering the prediction of macro-scale and long-term crack formation, the Paris law was utilized in this research. Experimental work on fatigue life with this material was performed, and good agreement was found with the results obtained in FE modeling. The number of cycles for fatigue crack propagation attains up to a maximum of 40% of the final fatigue lifetime with a typical value of 15% in many cases. This physically based two-scale technique significantly advances fatigue research, particularly in power plants, and paves the way for rapid and low-cost virtual material analysis and fatigue resistance analysis in the context of environmental fatigue applications. [ABSTRACT FROM AUTHOR]

Knowing the importance of assuring their reliability and availability, prognosis and remaining useful life calculation (RUL) concepts are highly suggested to be applied in critical applications such as hybrid electric vehicles (HEV). In the electrical propulsion system of HEVs, the electrical machine is one of the most critical elements considering its cost and function. Most electrical machines used in HEVs are permanent magnet machines (PMM). Most severe faults in PMM that affect its normal operation are the result of demagnetization. However, applying prognosis to a real prototype to detect the presence of mechanical defects such as cracks in the magnet of PMM and calculating the RUL of this defective element are challenging. In this paper, we are going to take advantage of a finite element model already built for the PMM in the healthy state and the state where cracks of different depths are integrated into the magnet. After that, relevant vital parameters that are affected when this type of fault persists in the machine are collected. Then, prognosis is applied to detect the presence of the crack in one piece of magnet in the electrical machine. Following this, the RUL calculation is performed to predict the remaining time before the crack propagates and a total fracture occurs in the magnet. The method used to execute the prognosis is the hidden Markov model (HMM). The RUL calculation will be performed using Paris equation, being the most important equation that models the growth and propagation of cracks [ABSTRACT FROM AUTHOR]

Paris' power law is commonly used to describe transverse thermal cracking propagation in asphalt concrete (AC) pavements. In its most common format, it relates the rate of change in the crack length per cycle to changes in either the stress intensity factor K or the energy release. The parameters defining this relationship for ACs can be obtained using the Texas cyclic Overlay Test (OTR). This paper describes two numerical approaches for simulating the OTR using the extended finite element method (XFEM). The first uses the direct low-cyclic fatigue (LCF) approach and the second uses the virtual crack closure technique (VCCT). Comparisons of the model predictions to laboratory OTR measurements for six mixtures suggest that the XFEM model coupled with VCCT is better suited for simulating the OTR. The model output includes the crack length and the energy release rate ERR (i.e. ${\rm \Delta }J_R$ Δ J R ) as cracks propagate. This data was used to fit the modified Paris' law parameters ${A}^{\prime}$ A ′ and ${n}^{\prime}$ n ′ as a function ${\rm \Delta }J_R$ Δ J R . Subsequently, the traditional A and n Paris' power law parameters were fitted by estimating the corresponding ΔK. Using this model, it was possible to efficiently estimate the AC cracking parameters using as input only the tensile modulus and the critical ERR. [ABSTRACT FROM AUTHOR]

Corrosion and crack defects often exist at the same time in pipelines. The interaction impact between these defects could potentially affect the growth of the fatigue crack. In this paper, a crack propagation method is proposed for pipelines with interacting corrosion and crack defects. The finite element models are built to obtain the Stress Intensity Factors (SIFs) for fatigue crack. SIF interaction impact ratio is introduced to describe the interaction effect of corrosion on fatigue crack. Two approaches based on extreme gradient boosting (XGBoost) are proposed in this paper to predict the SIF interaction impact ratio at the deepest point of the crack defect for pipelines with interacting corrosion and crack defects. Crack size, corrosion size and the axial distance between these two defects are the factors that have an impact on the growth of the fatigue crack, and so they are considered as the input of XGBoost models. Based on the synthetic samples from finite element modeling, it has been proved that the proposed approaches can effectively predict the SIF interaction impact ratio with relatively high accuracy. The crack propagation models are built based on the proposed XGBoost models, Paris' law and corrosion growth model. Sensitivity analyses regarding corrosion initial depth and axial distance between defects are performed. The proposed method can support pipeline integrity management by linking the crack propagation model with corrosion size, crack size and the axial distance. The problem of how the interaction between corrosion and crack defects impacts crack defect growth is investigated. [ABSTRACT FROM AUTHOR]

In this paper, the extended isogeometric analysis based on Bézier extraction of NURBS is applied for Investigating stress intensity factor and fatigue life in the two-dimensional crack problems with thermal and mechanical cyclic loading. By transforming NURBS function to linear combination of Bernstein functions defined over C0-continuous Bézier elements, the extended isogeometric analysis can be implemented in the extended finite element method framework. Grid points around the crack line and crack tip are identified by the level set representation. Then, discontinuous enrichment functions are added to the isogeometric analysis approximation. Thus, this method does not require remeshing. The interaction integral method and Paris law has been used to extract stress intensity factor and evaluate fatigue life, respectively. Numerical examples are examined to validate the efficiency of the proposed method. The effect of adaptive refinement strategies on computational cost and convergence is studied. Numerical examples showed that the presented method produces highly accurate results, yet it is beneficial to implement. [ABSTRACT FROM AUTHOR]

• Mode II fatigue crack growth is characterized at the steel-to-composite interface. • Displacement and load controlled ENF and 4ENF test methods are compared. • Novel method is proposed to determine crack growth by shear strains from DIC. • Friction and geometrical non-linearity is considered by finite element models. In this paper, mode II fatigue crack growth properties of the composite-to-steel interface are characterised through different test configurations, namely ENF and 4ENF tests. Different loading types including force control and displacement control methods are compared. An innovative shear strain based method is proposed for monitoring the mode II crack growth at the bi-material interface through Digital Image Correlation (DIC). A 3D finite element model with Virtual Crack Closure Technique (VCCT) is built and used for obtaining the strain energy release rate (SERR) to investigate the effect of geometrical nonlinearity, friction at the interface and steel yielding, as well as to verify the mode mixity. The results show that the standard 3-point bending ENF specimen can be unstable under force control and sweeps narrow SERR range by a single test under displacement control. The 4-point bending 4ENF test shows stable crack propagation and clear SERR developing trend. More pronounced geometrical nonlinearity and friction effect exist for 4ENF test which can be considered when interpreting the Paris curves by a nonlinear finite element model. [ABSTRACT FROM AUTHOR]

• The CRTS Ⅲ slab track model with prefabricated cracks is established by extended finite element method. • The stress intensity factors (SIFs) at the tips of cracks on the track slab under train load are solved. • The effects of the crack length and depth on the SIFs of three types of cracks are discussed. • The variations of crack growth rate calculated by Paris' semi-empirical during service are analyzed. Microcracks may occur in Chinese Railway Track System type III (CRTS III) ballastless track slabs during service, and it is necessary to investigate their potential propagation under train load, which could lead to slab deterioration and affect the durability of the track structure. In this paper, based on the fracture mechanics theory, the stress intensity factors (SIFs) at the tips of transverse crack, longitudinal crack and vertical crack on the CRTS III track slabs under train load are solved by the extended finite element method (XFEM) in Abaqus software. The changes of SIFs at the crack tips during the passage of the train are analyzed, and the effects of the crack length and depth on the SIFs of the three types of cracks are discussed under train load. Crack growth rate is calculated using Paris' semi-empirical law to estimate slab life. The results show that the train load contributes to the propagation of transverse and vertical cracks in the vertical direction and inhibits the longitudinal cracks. When the middle of the sixth vehicle is above the crack, the SIFs at the tips of the crack reach their maximum values. The SIF of vertical cracks exceeds the fracture toughness at a certain depth. The fatigue load cycles calculated by Paris' semi-empirical law suggest that maintenance will not be required due to insufficient propagation under train load during service. [ABSTRACT FROM AUTHOR]

The paper deals with an optimization problem related to axisymmetric membrane shells made of homogeneous, linear and isotropic materials and subject to a cyclic internal pressure. The optimization problem considers the possible crack growth in the shell as a structural constraint, which is accounted for by the well-known Paris law, and hence obeys the Linear Elastic Fracture Mechanics (LEFM) principles. The design variables are the meridian shape and the thickness distribution along the axis of the shell. After recalling the general background on the mechanics of thin-walled shells, the optimization problem is stated, formulated and solved in closed form by means of Pontryagin's Principle, showing two LEFM-based design criteria capable to help the designer in selecting the desired elastic performance through which the shell undergoes. It is shown that the derived optimal solutions are ellipsoids with variable thicknesses, whose distributions depend on the mass constraint and the applied pressure. Nevertheless, the optimal shapes guarantee the uniformity of either the meridian or the hoop stress, and such uniformity has been verified within a numerical example by an accurate finite element analysis. • The maximum volume problem for axisymmetric membrane shells is formulated. • The shells are subject to cyclic pressure and mass constraints. • The membrane theory of shells and Paris law are taken into consideration. • Optimal shapes are derived analytically by means of Pontryagin's Principle. • Two design criteria are given for uniform meridian and hoop membrane stresses. • The finite element method confirms the theoretical stress behavior. [ABSTRACT FROM AUTHOR]

• Implementation of slow growth design strategy for bonded joints/patch repairs for primary aircraft structures, consistent with FAA guidance. • Static and fatigue testing of a novel specimen configuration to identify the entire disbond crack growth process. • Indication of slow growth management approach feasible for bonded joints/patch repairs if the doubler/patch is designed to be sufficiently long. • Establishment of modified Paris law for predicting allowable fatigue life and determining inspection interval, in accordance with FAA guidance. • Potential solution for maintenance cost reduction for primary aircraft structures. The applicability of a damage slow growth management strategy to bonded joints/patch repairs of primary aircraft structures was evaluated through an experimental and computational study. Fatigue tests were conducted to investigate the entire process of disbond growth from initiation up to joint ultimate failure. The residual static strength of the joint as a function of disbond length was established using finite element modelling, in which the mesh size was calibrated using the static strength of the specimens measured in room temperature and dry (RD) and hot-wet (HW) conditions, based on the characteristic distance approach. A virtual crack close technique (VCCT) approach was utilised to assess the strain energy release rates (SERRs) as a function of disbond crack length. The measured disbond growth rates were correlated with the SERRs using a modified Paris law that enabled prediction of joint fatigue life. The fatigue test results indicated that for a joint having a sufficient static strength safety margin under a typical fatigue loading that would propagate disbond, the disbond growth would be stable in a particular length range. Thus, the slow growth approach would be feasible for a bonded joint/patch repairs if the patch is designed to be sufficiently large to allow extended damage propagation (whilst in the case when patch size must be limited, safe-life design for the patch termination region in critical repairs must be considered. Should disbond growth occur in this case, the joint must be repaired or replaced). The work presented in this paper validated the framework/procedure proposed previously by the authors (Tanulia et al., 2020) for managing damage slow growth in bonded joints/patch repairs. In the last part of this paper the planned follow-on research is briefly described. [ABSTRACT FROM AUTHOR]

• The Johnson-cook damage model, traction separation and Paris law equations are incorporated in the XFEM model to predict the formation of spalling, crack propagation and fatigue life for the spur gear respectively. • 3D finite element analysis was performed to determine the fatigue life of the spur gear using with and without spall using different crack lengths and backup ratio. • Numerical modeling of spur gear developed and results showed that the increase in backup ratio from 0.3 to 3.3, an exponential increase in the fatigue life with and without spall. • The spalling depth obtained on the spur gears with backup ratio 0.3, 0.5, 1.0, and 3.3 are within the range of 20–100 μm. Spur gears are most commonly used to transmit power, and speed variation from one shaft to another shaft. Spalling more frequently occurs surface fault in the gears and sometimes it causes severe damage to the gear tooth. This paper focuses on the effect of spalling on the fatigue life of spur gear. The simulation study is conducted in two parts. In the first part, the Johnson-Cook Damage model is used for the spall generation on the tooth surface. After that, the spalling results are imported as input into the crack initiation /crack propagation model and calculated the rate of crack growth of fatigue crack is based on Paris law implemented in user-defined subroutine Abaqus software. User-defined subroutine code is also validated with the comparison of the numerical and experimental results available in the literature. Cracks with different initial lengths are placed in the deeper cavities of spalling and the crack propagation analysis is conducted using XFEM. The study is conducted for four different backup ratios with cracks of three different initial lengths. The fatigue crack growth life of spur gears is investigated using different crack lengths and backup ratios. Further, a comparison has been made between the fatigue life of a spur having a spalling fault with the fatigue life of spur gear that does not have spalling fault present on its surface. It has also been found in this study that spur gear having cracks originating from the spall region have a less fatigue life as compared to the spur gear without spalling. With the increase in backup ratio from 0.3 to 3.3, an exponential increase in fatigue life is observed. However, the fatigue life of spur gear without the presence of spalling fault has higher fatigue for all backup ratios. [ABSTRACT FROM AUTHOR]

A 3D Finite Element Analysis model was developed to describe the temperature distribution inside a novel neutron transparent high-pressure sample assembly. The validity of the model was established by conducting experimental validation. The Finite Element Analysis model was utilised to evaluate the sample assembly's temperature gradients and optimise its geometry and components. The results indicate that the discrepancy between the temperature recorded in the laboratory using thermocouples and the temperature calculated by the Finite Element Analysis model was only 4% under the assumption that the thermocouple was positioned in the middle of the sample assembly. The models further demonstrate that the Finite Element Analysis approach is a valuable tool for optimising the sample assembly by considering the impact of different materials and variations in the shape of its components. [ABSTRACT FROM AUTHOR]

Context: At the interface of W-Cu after direct jointing, diffusion layers with a thickness of approximately 22 nm are present but often overlooked in simulations of mechanical properties. In this study, an interface model with a W-Cu diffusion layer is developed using molecular dynamics (MD). The effects of the diffusion layers on the elastic–plastic behaviors, dissipation mechanisms, and fracture properties of the interface are analyzed under mode-I (perpendicular to the interface) and mode-II (parallel to the interface). The results demonstrate that the interface model with a diffusion layer exhibits superior mechanical properties under mode-I and mode-II loading compared to the model without a diffusion layer. Furthermore, a multi-scale method based on the classical Paris law is proposed, combining MD and finite element methods to investigate the fatigue crack propagation of W-Cu bimetallic composites under cyclic loading and predict their fatigue life. The findings of this study are meaningful for improving the mechanical properties of W-Cu interface materials, predicting the material's lifespan, and guiding related engineering applications. Methods: In this study, the molecular dynamics simulations have been carried out by using the Large-scale Atomic/Molecular Massively Parallel Simulator (LAMMPS). The visualization of results is performed using the Open Visualization Tool (OVITO). Common neighbor analysis (CNA) and dislocation analysis (DXA) in OVITO have been employed to capture the structural evolution. Finite element method simulations are performed in Ansys Workbench. [ABSTRACT FROM AUTHOR]

This paper presents a novel method to construct a plate element enveloping crack tip in the extended finite element method (XFEM) frame for crack growth simulation. The element enveloping a crack tip is sub-partitioned into several triangular quarter-point singular elements around the crack tip. The sub-triangular singular element cut by the crack, like the ordinary elements separated by the crack in other regions, is enriched with the Heaviside function. As the sub-partition scheme retains the original boundary of the crack tip element and the discontinuity of the entire crack is reproduced by the Heaviside enrichment, the proposed method can model cracks independent of the background mesh. Using the singular elements instead of analytical asymptotic functions employed in the conventional XFEM allows to reflect the crack tip singularity for more fracture scenarios. The additional nodes created by the sub-partition act as internal nodes of the crack tip element, thus the classical and enriched degrees of freedom (DOFs) on these nodes can be eliminated through an element-level condensation, which could reduce the condition number of the system matrix. Crack growth in plates and shells under fatigue loading is described by using Paris' law. The performance of the proposed method is investigated through stress intensity factors (SIFs) prediction, convergence study, and fatigue crack growth analysis in several examples of cracked plates and cylindrical shells. • A novel method for constructing crack tip element is developed based on XFEM. • The crack tip element is sub-partitioned into several triangular singular elements. • The sub-triangular singular element cut by crack is enriched with the Heaviside function. • All the DOFs on the sub-partition-induced nodes are eliminated through element-level condensation. • Several examples including fatigue crack growth in cylindrical shells show effectiveness and accuracy of the method. [ABSTRACT FROM AUTHOR]

Gluten pellets are readily broken on packaging and transportation. This study aimed to research mechanical properties (elastic modulus, compressive strength, failure energy) with different moisture contents and aspect ratios under different compressive directions. The mechanical properties were examined with a texture analyzer. The results revealed that the material properties of the gluten pellet are anisotropic, and it was more likely to cause crushing during radial compression. The mechanical properties were positively correlated with the moisture content. The aspect ratio had no significant effect (p > 0.05) on the compressive strength. The statistical function model (p < 0.01; R2 ≥ 0.774) for mechanical properties and moisture content fitted well with the test data. The minimum elastic modulus, compressive strength, and failure energy of standards-compliant pellets (with moisture content less than 12.5% d.b.) were 340.65 MPa, 6.25 MPa, and 64.77 mJ, respectively. Moreover, a finite element model with cohesive elements was established using Abaqus software (Version 2020, Dassault Systèmes, Paris, France) to simulate the compression rupture form of gluten pellets. The relative error of the fracture stress in the axial and radial directions between the simulation results and the experimental value was within 4–7%. [ABSTRACT FROM AUTHOR]

The 7075 aluminum alloy is a promising material for the aerospace industry due to its combination of light weight and high strength. This study proposed a method for predicting fatigue crack initiation of the 7075 aluminum alloy by crystal plasticity finite element analysis considering microstructures. In order to accurately predict the total fatigue life, it is necessary to calculate the number of cycles for fatigue crack initiation, small crack growth, and long crack growth. The long crack growth life can be estimated by the Paris law, but fatigue crack initiation and small crack growth are sensitive to the microstructures and have been difficult to predict. In this work, the microstructure of 7075 aluminum alloy was reconstructed based on experimental observations in the literature and crystal plasticity simulations were performed to calculate the elasto-plastic deformation behavior in the reconstructed polycrystalline model under cyclic deformation. The calculated local plastic strain was introduced into the crack initiation criterion (Tanaka and Mura, 1981) to predict fatigue crack initiation life. The predicted crack initiation life and crack morphology were in good agreement with the experimental results, indicating that the proposed method is effective in predicting fatigue crack initiation in aluminum alloys. From the obtained results, future issues regarding the prediction of fatigue crack initiation were discussed. [ABSTRACT FROM AUTHOR]

The extended finite element (XFEM) has been applied to investigate fatigue crack growth in engineering components containing different types of material irregularities. The standard approximations of finite element method are enriched with additional functions by employing the partition of unity approach. In order to keep track of discontinuities in the domain, level set method is employed. Fatigue crack growth in presence of different material irregularities, such as elliptical, rectangular, hexagonal and octagonal discontinuities, has been the main focus of the study. The effect of geometry, position and material properties of these discontinuities on fatigue behavior of the cracked specimen has been addressed. The fatigue life of the cracked component has been estimated by the generalized Paris law. The mixed mode stress intensity factors have been evaluated by the domain-based interaction integral approach. Several numerical problems are solved by XFEM to study the fatigue crack growth behavior of cracked specimens containing different types of material irregularities. [ABSTRACT FROM AUTHOR]

• Plastic clay can be modelled in drained conditions. • FEM-3D calculations are appropriate to reproduce on site recorded displacements. • SRM underestimates the props loads. As part of the Grand Paris Express project, Fort d'Issy-Vanves-Clamart (FIVC) is one of the 60 new metro stations involving a 32 m deep excavation in layered soils made of limestones and clays. The support system was subject to a comprehensive monitoring program to assess the behavior of the soil and the structure during the works [22]. It comprises wall displacements using inclinometers, bending moments using fiber optic, struts and beams loads using strain gauges and earth pressures at the soil/wall interface using pressure cells. The present paper presents the back analysis done using Finite Elements Models (FEM) in 2D and 3D and, the subgrade reaction method (SRM). The results depict a great consistency between FEM and SRM in terms of reproducing, at the same accuracy level, the wall displacements and bending moments. However, the earth pressure redistribution behind the wall and the props loads are significantly underestimated by SRM (40%) especially for deep excavations. Only FEM can reproduce the measurements since arching effect is allowed within the soil. The present back analysis provides adjustment to the input soil parameters in compliance with their variation range. The resulting set of parameters could be used for an optimization purpose in future designs of deep excavations in similar ground conditions. [ABSTRACT FROM AUTHOR]

Advances in machine systems and scanning technologies have increased the use of selective laser melted materials in industrial applications, resulting in almost full-density products. Inconsistent mechanical behavior of components under cyclic stress is caused by microstructure and porosity created during powder melting. The extended finite element method, XFEM, was used to imitate crack propagation utilizing an arbitrary fracture route to study fatigue crack growth in additively produced fatigue specimens. The influence of loading level and testing frequency on fatigue life was studied using fracture energy rate curves. Micro-computed tomography (µ-CT) scans offer 2D images in angular increments. There are several ways to reduce the number of faces and vertices. Opensource software was used to isolate the cylindrical shell from interior pores and create finite element models from µ-CT projections. All simulations were on supposedly cylindrical fatigue specimens made by selective laser melting (SLM) based on previous experimental results of the authors. Crack propagation rate curves were utilized to evaluate the effects of loading level and testing frequency. At larger loads, the fracture area increases abruptly at 3E3 cycles, then stabilizes at 4E4 cycles in Al alloys in comparison to Ti-6Al-4V alloys. Crack propagation rate curves may be used to determine Paris constants based on the applied stresses. [ABSTRACT FROM AUTHOR]

• Finite element analysis on the surface crack growth in steel pipes reinforced with CRS. • The FE model is validated by the experimental results. • Based on the FE model and Paris' law, surface crack growth rate is quantitatively evaluated. • Revealing the mechanism of CRS reinforcement on the surface cracked steel pipes. • Indicating the key influential parameters of CRS reinforcement on surface cracked steel pipe. This paper conducts a numerical analysis on the external surface cracked steel pipes reinforced with Composite Repair System. A three-dimensional finite element (FE) model is developed to calculate the Stress Intensity Factor (SIF) of the surface crack, and the crack growth process is evaluated by the Paris' law. The effect of FRP-to-steel interfacial bond condition on the SIF evaluation has been considered by incorporating the cohesive zone modelling. Then the FE model is validated by the experimental results. Thereafter, major issues including "interfacial bond condition" and "reinforcement effectiveness and influential parameters" have been discussed. The results indicate the reinforcement effectiveness on reducing the SIF owes to the decreasing of stress magnitude and the crack-bridging effect. Because of the crack-bridging effect, composite reinforcement performs more efficiently on reducing the SIF at the surface point than at the deepest point of the surface crack. The negative influence of the FRP-to-steel bond condition on the surface crack growth is not as significant as on reinforcing through-thickness cracks. However, since the interfacial stiffness is sensitive to the adhesive thickness, choosing an ideal adhesive thickness to acquire a good reinforcement effectiveness and to avoid potential interfacial bond failures is recommended. [ABSTRACT FROM AUTHOR]

Based on the rupture accident of the stator blade of a high-pressure steam turbine diaphragm, the strength of the crack at the connection between the blade and the outer ring was calculated by using finite element method. The relationships between the crack stress intensity factor and the crack location, crack depth and crack size were analyzed, and the factors that could affect the crack strength are obtained. To study the effect of crack on the life of steam turbine diaphragm, an initial crack was assumed to exist at the stress dangerous point of the diaphragm. The relationship between the initial crack size and the residual life, as well as the relationship between the extended life and the extended length were obtained by Paris formula. It provides a reference method for the preliminary estimation of the residual life of the crack in the actual maintenance work. [ABSTRACT FROM AUTHOR]